Thermally Conductive Polyurethane Adhesive for Energy Storage
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing thermally conductive adhesives used in electric vehicles compromise mechanical properties and electrical insulation when increasing thermal conductivity, making them unsuitable for safely and durably fixing energy storage devices.
Innovation Solution
A thermally conductive adhesive composition combining fillers with different thermal conductivities, specifically a polyol with a molecular weight of 700 to 12000 g/mol, a chain extender, and two types of fillers (A1 with ≤50 W/mK and A2 with ≥80 W/mK) within specific weight percentages, to achieve high thermal conductivity while maintaining mechanical properties and electrical insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If high thermal conductivity fillers are incorporated into the adhesive composition, then thermal conductivity is improved, but mechanical properties such as tensile modulus, tensile elongation and strength deteriorate
Solution Approach 1:
The patent applies local quality by using two different types of fillers with different properties: filler A1 (lower thermal conductivity ≤50 W/mK, higher volume resistivity ≥10^12 Ωcm) and filler A2 (higher thermal conductivity ≥80 W/mK, lower volume resistivity ≤10^10 Ωcm). Each filler is distributed throughout the adhesive composition to provide localized functions - filler A1 provides electrical insulation while filler A2 provides thermal conduction pathways, thereby resolving the contradiction between thermal conductivity and mechanical properties
Solution Approach 2:
The patent employs composite materials by combining filler A1 and filler A2 in specific weight ratios (filler A1: 30-80 wt.-%, filler A2: 1-15 wt.-%) within the polyol-based adhesive matrix. This composite filler system creates a synergistic effect where the lower conductivity filler maintains mechanical integrity and electrical insulation, while the higher conductivity filler establishes thermal conduction networks, achieving both high thermal conductivity and preserved mechanical properties
2Temperature
If high thermal conductivity fillers are incorporated into the adhesive composition, then thermal conductivity is improved, but volume resistivity deteriorates
Solution Approach 1:
The patent applies local quality by using two different types of fillers with different properties: filler A1 (lower thermal conductivity ≤50 W/mK, higher volume resistivity ≥10^12 Ωcm) and filler A2 (higher thermal conductivity ≥80 W/mK, lower volume resistivity ≤10^10 Ωcm). Each filler is distributed throughout the adhesive composition to provide localized functions - filler A1 provides electrical insulation while filler A2 provides thermal conduction pathways, thereby resolving the contradiction between thermal conductivity and mechanical properties
Solution Approach 2:
The patent employs composite materials by combining filler A1 and filler A2 in specific weight ratios (filler A1: 30-80 wt.-%, filler A2: 1-15 wt.-%) within the polyol-based adhesive matrix. This composite filler system creates a synergistic effect where the lower conductivity filler maintains mechanical integrity and electrical insulation, while the higher conductivity filler establishes thermal conduction networks, achieving both high thermal conductivity and preserved mechanical properties
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The adhesive composition achieves a balance of high thermal conductivity, excellent mechanical properties, and high volume resistivity, ensuring safe and long-lasting assembly of energy storage devices without compromising electrical insulation.
Implementation Method 1
an increase in thermal conductivity adversely effects the mechanical properties
Data Source
AI summary
The present invention relates to a thermally conductive adhesive composition having excellent mechanical properties and a method of manufacturing the same. Further, the present invention relates to method of manufacturing an article comprising the thermally conductive adhesive composition and articles obtainable by the described method.